Coating and a method of applying the same to fibrous surfaces



aienied Jan, 2, I940 STATES PATENT OFFICE QOATING AND A METHOD OF APPLYING THE SAME TO FIBROUS SURFACES David Pelton Moore, Avon Park, Fla.

No Drawing. Application December 18, 1935, Serial No. 55,007. Renewed March 21, 1939 8 Claims.

when used on pile fabrics locks the fibre in the web.

Another object of the invention is the provision of a coating for carpets and rugs, which holds the same fiat upon the floor and against sliding or slipping when walked or trod upon, and which will permit the carpet or rug to be rolled evenly when not in use.

Still another object of the invention is the provision of a coating to water-proof fibrous or fabric sheets for roofing, flooring, andtents or awnings.

Still another object of this invention is the use of an aqueous dispersion of rubber or latex with a powdered calcium compound, such as Portland cement, plaster of Paris and/or unslaked powdered lime, any one of which forms a combined dehydrating and vulcanizing agent, so that when they are mixed upon a fibrous surface, the rubber is congealed and adhesively attaches itself to the surface, whether the latex is sprayed first or last, with relation to the powder.

Still another object of the invention is the provision of novel methods of applying the coating upon the sheet.

To carry out this invention, the discovery disclosed in the British patent to Wills, No. 202,652, is basically used and modified to fit this particular purpose, an aqueous dispersion of rubber or rubber latex and a Portland cement, plaster of Paris and/or pulverized unslaked lime, that is a calcium compound of the above character, being used in such a manner as to be spread evenly over the surface of the fabric to form a congealed rubber coating (similar to vulcanized rubber) without'heating artificially, this being a very desirable feature for use with fibrous or fabric sheets of any nature, as it does not deleteriously affect the sheets and the rubber has-a longer life.

In carrying the present invention in practice," there are several methods of applying the materials, but preferably, the sifted very fine calcium compound powder in dry form and the latex (80% solution or less) are simultaneously sprayed upon the stretched surface of the sheet, the nozzles supplying each being so disposed that the atomized latex will receive the powder dust and carry t on to and into the interstices of the material of the sheet, dependent upon the pressure used and as it takes only about 1 to 5 minutes for the sprayed materials to produce a congealed rubber after engaging the surface of the fabric, 5 it is evident that the combination will be cohesively attached to the sheet, so that a flexible and elastic water-proof coating will result. The coating may be as thin or as thick as required,

this being according to the purpose for which it 1 is to be used. That is carpets, mats or rugs, will or may require a greater amount than will canvas, cotton and other fibrous sheets that are not used to be trod upon. This treatment will render many fabrics more durable, and when placed 15 upon the outer surface, a good rubberized roofing or surface for roofs, tents, awnings, kitchens, bath rooms, and like surfaces is provided.

Another method is to dust the powder upon the stretched sheet, and then spray the latex thereon, at sufiicient pressure to impregnate the powder and the immediate surface of the sheet sufficiently far to obtain the desired grip of the rubber coating in or on to the surface of the sheet. I

In manufacturing this rubber surface sheet 25 for roofing and the like, the roll of material is fed and while in transit, the coating material applied so that before the take up roll receives the finished sheet the rubber has congealed and is not "tacky or sticky, thus making it possible 30 to produce the present material in rolls similarly to tarred roofing paper. The coating may be put on light cotton sheeting, paper or fine wire mesh sheets.

Other methods may be employed to secure an 35' even distribution of the powder and latex over the surface to be treated, and still be within the scope of the invention, it being essential that the powder as a dust and latex, be upon and in the surface before the hydrating element of the 40 By adding coloring to the powder and/or the latex, various colors can be given the complete surface.

This coating when used with the knitted pile fabric such as described in my U. S. Letters Patent No. 1,791,741 permits the use in such fabric of a what is known as slippery or non-barb fibers, such as mohair, reindeer hair, rabbit hair, camel's hair, alpaca, or any combination thereof, as the adhesive quality of the coating tends to lock the knitted portions of these fibers firmly in with the basic web of the fabric. As it also renders the fabric water-proof on this surface, causes the same to lie fiat, and renders it nonslipping on the floor, a very cheap and desirable fioor covering results. It is also possible to use this coating very lightly, to convert this knitted pile fabric carrying long animal hair, in to artificial furs and fur trimmings.

The amount of latex to powder may be varied in accordance with the thickness of the coating desired. That is when it is desired to just barely coat the fabric, the powder dust is very lightly sifted, and a very small amount with a proportionate amount of the latex is sprayed on the fabric, or it may be heavily applied; or even in some cases two or more coats may be applied successively to increase the thickness. Varying pressures may be employed as a light porous fabric will require less than heavy or dense fabric, and where so desired both surfaces, one at a time, of the fabric may be coated.

The preferable proportions of the calcium compound dust and latex combination is about as follows:

Ounces Rubber latex (80%) 2 to 4 Calcium compound dust to 2 These proportions may vary, however, as in some cases the latex may be original sap, ammoniated only, and which would necessitate a greater quantity of the'powder, to take care of the excess water.

From the foregoing, it is evident that a fibrous sheet of any nature may be water-proofed, by the cohesion thereto on one or both surfaces of this coating; that heavier fabrics such as canvas or burlap may be treated with coatings to render them water-proof and for use for flooring, roofing and tents, or even for wall coverings; while carpets, rugs, and mats whether of the regular weave or the knitted pile fabric of my before mentioned patent may be given a coating'that locks the materials firmly together, permits the fabric to be put in rolls, causes the fabric to lie fiat upon the floor, and holds the same against slipping when walked or trod upon.

It is also possible to use paper as the rubber support, or in fact any porous support as fine wire mesh, cotton, linen, and weaves of other fibers, as the latex and powder combination will congeal on any such support. r

With satisfactory results the latex may be first applied to the sheet in any desired manner as by spraying, and while wet the powder is then dusted evenly thereover and smoothed slightly, if desired to produce an even adhering coating. Also a thin coating of latex'may besprayed immediately on the powdered or-dusted surface. In this'latter instance the rubber in the latex coatings, that is,

that directly on the sheet and the one on the powder, are congealed and form a slightly thicker coat on the sheet.

Color may be put in the powder in a dry form,

so that the congealed surface will take on such color. Auramine O or ocre will give yellow, crimson red a desired red, and Prussian or China blueseveral blues, all colors preferably being alkali colors. In fact many more than the above, that subjected to acalender.

\ are unaffected by the ammonia of the latex, can

be used with striking results.

In order to render the present coating fireproof or fire resisting, there can be mixed with the powder, powdered asbestos. A coating formed with asbestos added will not ignite when a lighted cigarette is thrown thereon'thus making this type of coating especially desirable for movable and fixed awnings. The asbestos coated material makes a durable and waterproof wall covering, and may be made in various colors and designs.

As in the Grimon-Sanson Patent No. 1,476,226, I prefer to use a dried cork powder treated with a water solution of carbonate of soda as it has less deleterious effects upon the rubber element. This powder can be applied as in this patent or it may be mixed with the congealing agent and dusted upon the latex covered surface as one powder, spread and calendered to the desired thickness. Or the powder may be spread or dusted on the surface and the latex applied last, and then if desired calendered. The cork,particles are rendered approximately the size of the cement, plaster of Paris or lime particles, and the proportions may vary as from 25% of cork to of powder up to 50-50 proportions. Also the cork and powder may have a coloring agent therein to give'the desired color to the coating.

What is claimed is:

1. A process for coating flexible porous sheets, which consists in feeding ,the'sheet from a roll in stretched condition, distributing simultaneously and from two different sources a finely divided dehydrating and setting calcium compound and an aqueous dispersion of rubber, thereby producing a uniform adhering waterproof coating which will congeal into a non-tacky, condition before the sheet is wound on a take up roll, and winding the coated sheet on the take up roll.

2. The processes claimed in claim 1, wherein there is incorporated with the calcium compound a coloring agent.

3. The process as claimed in claim 1, wherein there is incorporated with the calcium compound cork dust.

4. The process as claimed in claim 1, wherein there is incorporated with the calcium compound cork dust and a coloring agent.

5. The process as claimed in claim there is incorporated with thecalcium compound powdered asbestos.

6. A process for coating fabric, which consists in feeding the fabric from a roll in a stretched condition, spraying simultaneously and from two different Sprayers a finelyv divided dehydrating and setting calcium compound and an aqueous dispersion of rubber, thereby producing a uniform adhering waterproof coating which will congeal into anon-tacky condition before the fabric is wound on the take up roll, and winding the coated sheet on the take up roll.

.7. A process as claimed in claim 1, wherein before the sheet is wound on the take up roll, it is 8. A process for coating a surface with a permanent rubber coating, which consists in distributing simultaneously and from two different sources a finely divided dehydrating and setting calcium compound and an-aqueous dispersion of rubber to thereby produce a uniform adhering, waterproof coatingwhich will congeal into a nontacky condition upon the surface.

DAVID PELTON MOORE.

1, wherein, 

